Power connector with integrated status monitoring

ABSTRACT

An electronic power connector. The electronic power connector includes at least one contact configured to electrically connect a power supply to a load, an insulating sleeve, and an electronic assembly. The insulating sleeve includes a sensor slot configured to receive a sensor and is configured to receive the at least one contact. The electronic assembly including a transformer winding configured to receive the at least one contact and sense a current.

RELATED APPLICATIONS

The present application claims priority to the U.S. Provisional PatentApplication No. 62/519,031, filed Jun. 13, 2017, the entire contents ofwhich is incorporated by reference herein.

FIELD

Embodiments relate to electrical power connectors.

SUMMARY

Electrical power connectors provide a connection between a power supplyand a load. Such electrical power connectors may be described in U.S.patent application Ser. No. 15/072,672, filed Mar. 17, 2016 and U.S.patent application Ser. No. 15/072,672, filed May 11, 2017, which arehereby incorporated by reference.

Power measurements can be used to monitor the power consumption of theequipment connected through an electrical power connector. In somecases, the ability to accurately measure the power consumption enablesan operator to allocate energy costs to various users based on the usageof the equipment. Several factors may affect the accuracy of suchmeasurements.

Internal and environmental monitoring, in particular temperature,current, and voltage, may be used to identify normal versus abnormaloperating conditions. Continuous measurement enables identification ofchanges in operating parameters that are out of acceptable ranges sothat an alert is triggered to notify the operators to the condition.Furthermore, data analytics and understanding the normal operatingparameters help provide the user with predictive, or preventive, alertsbefore a potential failure occurs due to environmental, installation, orinternal hardware anomalies.

In particular, this application relates to integrating sensingfunctionality and communication into a housing of a power connectiondevice. One example embodiment provides an electronic power connector.The electronic power connector includes at least one contact configuredto electrically connect a power supply to a load, an insulating sleeve,and an electronic assembly. The insulating sleeve includes a sensor slotconfigured to receive a sensor and is configured to receive the at leastone contact. The electronic assembly includes a transformer windingconfigured to receive the at least one contact and sense a current.

Another example embodiment provides a power connector. The powerconnector includes a sleeve and a contact carrier located within thesleeve. The contact carrier includes a contact transformer module havingat least one connector contact configured to electrically connect apower supply to a load, an insulating sleeve, and a transformer winding.

Another example embodiment provides a method of sensing variouscharacteristics of an electronic power connector. The method includesproviding a transformer winding around at least one contact, providing asensor slot proximate the at least one contact, the sensor slotconfigured to receive a sensor, sensing, via the transformer, a current,and sensing, via the sensor, a characteristic.

Other aspects of the application will become apparent by considerationof the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a power system according to one embodimentof the application.

FIG. 2 is a perspective view of an electrical power connector of thepower system of FIG. 1 according to some embodiments of the application.

FIG. 3 is a break away view of a contact carrier of the electrical powerconnector of FIG. 2 according to some embodiments of the application.

FIG. 4 is a break away view of a contact carrier of the electrical powerconnector of FIG. 2 according to some embodiments of the application.

FIG. 5 is a break away view of a contact carrier of the electrical powerconnector of FIG. 2 according to some embodiments of the application.

FIG. 6 is a break away view of a contact carrier of the electrical powerconnector of FIG. 2 according to some embodiments of the application.

FIG. 7 is a perspective view of a contact transformer module of thecontact carrier of FIG. 4 according to some embodiments of theapplication.

FIG. 8 is a perspective view of a contact transformer module of thecontact carrier of FIG. 4 according to some embodiments of theapplication.

FIG. 9 is a top view of a contact transformer module of the contactcarrier of FIG. 4 according to some embodiments of the application.

FIG. 10 is a perspective view of a carrier contact of the contactcarrier of FIG. 4 according to some embodiments of the application.

FIG. 11 is a perspective view of an insulating sleeve of the contactcarrier of FIG. 4 according to some embodiments of the application.

FIG. 12 is a top view of a contact carrier of FIG. 4 with an electronicassembly according to some embodiments of the application.

FIG. 13 is a perspective view of a contact carrier of FIG. 4 with anelectronic assembly according to some embodiments of the application.

FIG. 14 is a perspective view of the electronic assembly of FIG. 13according to some embodiments of the application.

FIG. 15 is a perspective view of the electronic assembly of FIG. 13according to some embodiments of the application.

FIG. 16 is a perspective view of a cover of the electrical powerconnector of FIG. 2 according to some embodiments of the application.

FIG. 17 is a perspective view of a second electronic assembly positionedwithin the cover of FIG. 16 according to some embodiments of theapplication.

FIG. 18 is a perspective view of an insulating cover for the cover ofthe electrical power connector of FIG. 2 according to some embodimentsof the application.

FIG. 19 is a perspective view of a cap for the cover of the electricalpower connector of FIG. 2 according to some embodiments of theapplication.

FIG. 20 is a top view of a transformer winding according to anotherembodiment of the application.

FIG. 21 is a top view of a contact carrier including the transformerwinding of FIG. 20 according to an embodiment of the application.

FIG. 22 is an example power system according to some embodiments of theapplication.

DETAILED DESCRIPTION

Before any embodiments of the application are explained in detail, it isto be understood that the application is not limited in its applicationto the details of construction and the arrangement of components setforth in the following description or illustrated in the followingdrawings. For ease of description, some or all of the example systemspresented herein are illustrated with a single exemplar of each of itscomponent parts. Some examples may not describe or illustrate allcomponents of the systems. Other exemplary embodiments may include moreor fewer of each of the illustrated components, may combine somecomponents, or may include additional or alternative components. Theapplication is capable of other embodiments and of being practiced or ofbeing carried out in various ways.

It should be understood that although the example system described is anelectrical connector system, the application may be applied to otherconnector systems including electrical connections. For example, alsoillustrated as a pin and sleeve device, in other embodiments, the powersystem may include a plug, receptacle, inlet or other separable powerconnection type.

FIG. 1 illustrates a power system 100 according to some embodiments. Thepower system 100 includes a power supply 105, a load 110, an electricalpower connector, or connector, 115, and a power supply cable 120. Insome embodiments, the power supply 105 is a single-phase power supplyoutputting a voltage within a range of approximately 100 VAC toapproximately 240 VAC. In other embodiments, the power supply 105 is athree-phase power supply outputting a voltage within a range ofapproximately 208 VAC to approximately 600 VAC. In some embodiments, thepower supply 105 is a direct-current power supply outputting a voltagewithin a range of approximately 350 VDC to approximately 450 VDC (forexample, 400 VDC). In other embodiments, the power supply 105 is adirect-current power supply outputting a voltage within a range ofapproximately 44 VDC to approximately 60 VDC (for example, 48 VDC). Inyet another embodiment, the power supply 105 is a direct-current powersupply outputting a voltage within a range of approximately 15 VDC toapproximately 30 VDC (for example, 24 VDC). The load 110 may be anyelectrical device or system configured to receive power.

FIG. 2 illustrates the connector 115 according to an embodiment of theapplication. The electrical power connector 115 is configured to providean electrical connection between the power supply 105 and the load 110.The connector 115 may be configured to handle twenty-amps, thirty-amps,sixty-amps, one-hundred amps, etc. As illustrated, the connector 115includes a contact carrier 200 and a sleeve connector 205. The contactcarrier 200 includes one or more power terminals 210 located on a firstend 215 of the contact carrier 200. Although not illustrated, thecontact carrier 200 may further include one or more second powerterminals located on a second end 220 of the contact carrier 200.Although illustrated as having four power terminals 210, the connector115 may include any number of power terminals and second powerterminals, for example one power terminal and one second power terminal,two power terminals and two second power terminals, three powerterminals and three second power terminals, four power terminals andfour second power terminals, five power terminals and five second powerterminals, etc. In some embodiments, the power terminals 210 areelectrically connected to the load 110 while the second power terminalsare electrically connected to the power supply 105.

FIGS. 3-6 illustrate the contact carrier 200 according to variousembodiments of the application. As illustrated in the exploded view ofFIG. 3, the contact carrier 200 may include, among other things, a shell300, a cover 305, one or more contact transformer (CT) modules 310, andan electronic assembly 315. The shell 300 may be formed of anon-conductive material, such as but not limited to, a plastic orsimilar material. The cover 305 is also formed of a nonconductivematerial, such as but not limited to, a plastic or similar material. Theshell 300, in conjunction with the cover 305, houses various componentsof the contact carrier 200.

The CT modules 310 each include one or more connector contacts 320 andone or more transformer windings 325. The one or more connector contacts320 provide an electrical connection between the power terminals 210 andthe second power terminals. The transformer windings 325 are configuredto receive the respective connector contacts 32.0 and sense currenttravelling through the respective connector contacts 320. In someembodiments, a three-phase power supply may he monitored using two setsof transformer windings 325. In some embodiments, at least one of the CTmodules 310 may be configured to receive a spacer 312 in addition to, orin lieu of, the transformer winding 325. In such an embodiment, thespacer 312 may further secure the at least one CT module 310. In someembodiments, the contact carrier 200 also includes one or moreinsulating sleeves 330. The insulating sleeve 330 is configured toreceive the one or more connector contacts 320. In some embodiments, theinsulating sleeve 330 is made out of a thermally conductive or thermallyinsulating material. Such an embodiment may improve thermalcommunication between the contacts 320 and one or more sensors (forexample, sensors 335 of FIGS. 7 &. 8).

The electronic assembly 315 may include control circuitry for theconnector 115. For example, the electronic assembly 315 may be aprinted-circuit board including a controller having an electronicprocessor and a memory. The electronic assembly 315 may include, or beelectrically and/or communicatively coupled to, one or more components,including but not limited to, the transformer windings 325, the one ormore sensors 335, and one or more antennas 340.

The electronic processor, of the electronic assembly 315, obtains andprovides information (for example, from the memory, the sensors 335,and/or the antennas 340), and processes the information by executing oneor more software instructions or modules, capable of being stored, forexample, in a random access memory (“RAM”) area of the memory or a readonly memory (“ROM”) of the memory or another non-transitory computerreadable medium (not shown). The software can include firmware, one ormore applications, program data, filters, rules, one or more programmodules, and other executable instructions. The electronic processor maybe configured to retrieve from the memory and execute, among otherthings, software related to the control processes and methods describedherein.

The memory can include one or more non-transitory computer-readablemedia, and includes a program storage area and a data storage area. Theprogram storage area and the data storage area can include combinationsof different types of memory, as described herein. The memory may takethe form of any non-transitory computer-readable medium.

FIGS. 7-9 illustrate a contact transformer (CT) module 310 including thecontact 320, the insulating sleeve 330, and the transformer winding 325,according to some embodiments. As illustrated, the insulating sleeve 330receives at least a portion of the respective contact 320. Additionally,as illustrated, the transformer winding 325 also receives at least aportion of the respective contact 320. In some embodiments, thetransformer windings 325 are high turns-ratio linear windings woundaround a respective magnetic core configured to be positioned around therespective contact 320. By positioning a length of the contact 320within the center of the respective transformer windings 325, currentcan be accurately sensed without exceeding the available geometryconstraints of the contact carrier 200. As illustrated, in someembodiments, the transform windings 325 are circular in shape. In otherembodiments, the transformer windings 325 may be Rogowski coils In yetother embodiments, the transformer winding 325 may be a magnetic corewinding having special geometry to fit around the contact 320 and/or inthe shell 300.

The transformer winding 325 may be coupled to the electronic assembly315 via transformer leads 340. The electronic assembly 315 may supplypower to and receives measurements from the transformer winding 325 viathe transformer leads 340. However, other embodiments, the transformerwindings 325 may be wireless coupled to the electronic assembly 315.

The amount of CT modules 310 contacted within the shell 300 of thecontact carrier 200 may correspond to the amount of power terminals ofthe contact carrier 200. In some embodiments, the CT modules 310 mayinclude a shield (not shown). In such an embodiment, the shield may beconfigured to cover the transformer windings 325. In some embodiments,shielding the windings 325 may further improve current sensing.

As illustrated, the insulating sleeve 330 of the CT module 310 mayfurther include a sensor slot 415. The sensor slot 415 is configured tocouple a respective sensor 335 to the CT module 310. In someembodiments, the one or more sensors 335 are configured to sense anelectrical characteristic, for instance a voltage, between the powersupply 105 and the load 110 or within the connector 115 and/or atemperature within the connector 115. In some embodiments, the sensor335 is configured to sense a temperature of (or proximate to) thecontact 320. As illustrated, in some embodiments, the sensors 335 areconfigured to fit inside the sensor slots 415 of the CT modules 310. Insome embodiments, the sensors 335 are thermistors, thermocouples, RTDs,or any similar sensor. For example, the sensors 335 are thermocouplewires configured to sense a temperature within the proximity of therespective contact 320. Other sensors 335 within the connector 115 mayinclude, but are not limited to, humidity sensors, current sensors, andvoltage sensors.

In some embodiments, the electronic processor is configured to calculatean effective environmental temperature. The effective environmentaltemperature, or minimum predicted operational temperature, is theeffective temperature in the environment surrounding the contact carrier200. The electronic processor may calculate the effective environmentaltemperature based on data from the sensors 335. The electronic processormay calculate the effective environmental temperature by using presentand previously obtained electrical and temperature measurements fromvarious other sensors (for example, sensors 335 of other CT modules 310)at various points within the connector 115. The effective environmentaltemperature may then be used to determine an abnormality within theconnector 115.

For example, in some embodiments the electronic processor collects aseries of current measurements from each of the sensors 335corresponding to one or more of the contacts 320 over time to develop atemperature rise curve for the contacts 320 and the connector 115. Theelectronic processor may then identify the contact 320 with the lowestmeasured temperature. The electronic processor may then calculate theexpected temperature rise for the lowest current. Under normalconditions (for example, in an unbalanced system), the contact 320 withthe lowest current may be the coolest. When the contact 32.0 with thelowest current does not exhibit the lowest measured temperature of thecontacts 320 within a predetermined error threshold, an abnormality maybe present.

The temperature rise may be subtracted from the measured temperature tocalculate the effective/predicted environmental temperature. Theelectronic processor may also calculate the temperature deviation foreach measured temperature for each contact 320 from the predictedeffective environmental temperature by comparing the temperature risefor each contact 320 to the expected temperature rise given the current.

As illustrated, in some embodiments each connector contact 320 includesa contact lead 417. The contact lead 417 may provide an electricaland/or communicative contact between the connector contact 320 and theelectronic assembly 315. For example, the contact lead 417 is providedas a direct contact for sensing the temperature within proximity of therespective connector contact 320, as described in more detail below.FIG. 10 illustrates the connector contact 320 according to such anembodiment. However, it should be understood other means to connect thesensor 335 to the electronics assembly 315 may be implemented (forexample, wireless communication).

FIG. 11 illustrates the insulating sleeve 330 according to someembodiments. The insulating sleeve 330 is configured to align theconnector contact 320, the sensor 335, and the contact lead 417 usingone or more ribs located inside the carrier. The insulating sleeve 330may also provide electrical isolation between components.

FIGS. 12-15 illustrate the electronic assembly 315 and antenna 340contained within the shell 300 of the contact carrier 200. Asillustrated in FIG. 12, in some embodiments the electronic assembly 315and antenna 340 are located between the CT modules 310, and thus thecontacts 320. Such a placement may eliminate interference whileproviding easy connection to the transformer windings 325 and sensors335. In some embodiments, in addition to sensors 335, the electronicassembly 315 may include, or be connected to, additional sensors. Insuch an embodiment, the additional sensors may include an additionaltemperature sensor configured to sense a temperature central to theconnector 115. Also in such an embodiment, the additional sensors maysense the temperature of one or more various points of the contactcarrier 200. Also in such an embodiment, the additional sensor mayinclude an ambient sensor for sensing an ambient temperature externalthe contact carrier 200 and/or the connector 115.

In the illustrated embodiments, the antenna 340 is routed from theelectronic assembly 315 along the outside wall of the shell 300 (forexample, inside of and/or outside of the shell 300). In someembodiments, the antenna 340 may be held in place by one or more slotsin support ribs and/or holes adjacent the outside wall. The antenna 340may be a dipole-type antenna, a loop-type antenna, a flat chip antenna,or any other known antenna. The antenna 340 is configured to wirelesslytransmit various characteristics, for example electricalcharacteristics, of the contact carrier 200. For example, the antenna340 may wirelessly transmit current, voltage, and temperature of thecontact carrier 200. In some embodiments, the characteristics arewirelessly transmitted to one or more external devices (for example, asmartphone, a tablet, a remote server, a cloud-based server, etc.). Insome embodiments, rather than, or in addition to, antenna 340, thecontact carrier 200 may include an input/output port. In such anembodiment, the various characteristics described above may betransmitted via physical coupling (for example, a wired connection).Although only one antenna 340 is illustrated, it should be understood insome embodiments the connector 115 includes more than one of the antenna340. Each of the antennas 340 are configured to support a differentfrequency range for different communication protocols (for example,Bluetooth, Zigbee, and the like).

Although illustrated within the sensor slot 415, in should be understoodin other embodiments, the sensor 335 may be positioned (alternatively orin addition to the sensor 335 within the sensor slot 415) anywherewithin the connector 115 (in particular, the contact carrier 200.) Insome embodiments, when the sensor 335 is configured to sense temperatureof, or in proximity of, a contact 320, the sensor 335 is configured tobe positioned within the cover 305 within proximity of the contact 320in lieu of or in addition to the sensor 335 positioned within the sensorslot 415. FIG. 16 illustrates temperature sensors 600 positioned withinthe cover 305. In some embodiments, the electronic assembly 315 isconfigured to he positioned within (or is integrated into) the cover 305in such an embodiment, the temperature sensors are coupled to theelectronic assembly 315. In other embodiments, as illustrated in FIG.17, the temperature sensors 600 are coupled to a second electronicassembly 602. The second electronic assembly 602 may include componentsand function similar to the electronic assembly 315. For example, thesecond electronic assembly 602 includes a second electronic processorand a second antenna (not shown) configured to wirelessly transmitvarious characteristics of the contact carrier 200. In some embodiments,the characteristics are wirelessly transmitted to one or more externaldevices. In some embodiments, the second electronic assembly 602 may beconfigured to communicate with the electronic assembly 315.

FIG. 18 illustrates an insulating cover 603 for the cover 305. Theinsulating cover 603 may be coupled to, or integral to, the cover 305 toequalize the internal temperature throughout the connector 115. Theinsulating cover 603 may also improve the ability of a temperaturesensor within the connector 115, for example, the temperature sensors600, to measure more accurately. In some embodiments, the insulatingcover 603 is molded out of thermally conductive material. As illustratedin FIG. 19, in other embodiments the cover includes thermally conductivematerial over-molded caps 604 with a sheet metal plate 605.

FIGS. 20 and 21 illustrate biased transformer windings 500 according toanother embodiment of the application. As illustrated, the biasedtransformer windings 500 may be configured to be receive the CT modules310. In such an embodiment, the biased transformer windings 500 may be aRagowski helical coil or a biased winding toroid. Such an embodiment mayenable the placement of the CT modules 310 into geometries that aretypically too small for a full transformer winding.

FIG. 22 illustrates a mechanical disconnection system 700. Embodimentsof the power connector described herein may be implemented as part of apower system including the mechanical disconnection system 700.

Thus, the application provides, among other things, an improved andsystem for sensing various characteristics of an electronic powerconnector.

What is claimed is:
 1. An electronic power connector comprising: atleast one contact configured to electrically connect a power supply to aload; an insulating sleeve configured to receive the at least onecontact, the insulating sleeve including a sensor slot configured toreceive a sensor; and an electronic assembly including a transformerwinding configured to receive the at least one contact and sense acurrent.
 2. The electronic power connector of claim 1, wherein thesensor is a voltage sensor.
 3. The electronic power connector of claim1, wherein the sensor is a temperature sensor.
 4. The electronic powerconnector of claim 3, wherein the temperature sensor is configured tosense at least one selected from the group consisting of a temperatureproximate to the contact, an ambient temperature, and an internaltemperature of the electronic power connector.
 5. The electronic powerconnector of claim 1, wherein the sensor slot is located at a first endof the insulating sleeve.
 6. The electronic power connector of claim 1,wherein the insulating sleeve is made of a thermally conductive orinsulating material.
 7. The electronic power connector of claim 1,wherein the power supply is a single-phase power supply having a voltageof approximately 100 volts AC to approximately 240 volts AC.
 8. Theelectronic power connector of claim 1, wherein the power supply has avoltage of at least one selected from the group consisting ofapproximately 24 volts direct current, approximately 48 volts directcurrent, and approximately 400 volts direct current.
 9. The electronicpower connector of claim 1, wherein the power supply is a three-phasepower supply having a voltage of approximately 208 volts AC toapproximately 600 volts AC.
 10. The electronic power connector of claim1, further comprising an antenna configured to transmit an electricalcharacteristic.
 11. The electronic power connector of claim 1, whereinthe transformer winding is biased around the contact.
 12. The electronicpower connector of claim 1, wherein the electronic power connectorfurther includes: a cover; and an insulating cover for the coverconfigured to equalize the internal temperature throughout theconnector.
 13. A power connector comprising: a sleeve; and a contactcarrier located within the sleeve, the contact carrier includes acontact transformer module having at least one connector contactconfigured to electrically connect a power supply to a load, aninsulating sleeve, and a transformer winding.
 14. The power connector ofclaim 13, wherein the transformer winding is configured to sense acurrent.
 15. The power connector of claim 13, wherein the contacttransformer module further includes a sensor slot configure to receive asensor.
 16. The power connector of claim 15, wherein the sensor is avoltage sensor.
 17. The power connector of claim 15, wherein the sensoris a temperature sensor.
 18. The power connector of claim 13, furthercomprising at least one antenna located within the sleeve, the antennaconfigured to transmit an electrical characteristic.
 19. The powerconnector of claim 13, wherein the transformer winding is biased aroundthe contact.
 20. The power connector of claim 13, wherein the powersupply has a voltage of at least one selected from the group consistingof approximately 24 volts direct current, approximately 48 volts directcurrent, and approximately 400 volts direct current.
 21. A method ofsensing various characteristics of an electronic power connector, themethod comprising: providing a transformer winding around at least onecontact; providing a sensor slot proximate the at least one contact, thesensor slot configured to receive a sensor; sensing, via thetransformer, a current; and sensing, via the sensor, a characteristic.22. The method of claim 21, wherein the characteristic is a voltage. 23.The method of claim 21, wherein the characteristic is a temperature. 24.The method of claim 21, wherein the transformer winding is biased aroundthe contact.